Composite weldable panel with embedded devices

ABSTRACT

A panel having a central panel element formed of a composite material, having peripheral edges formed of a weldable material, such as steel. In one form, the panel element is rectangular, and the panel element on two of its opposite edges have a corrugated profile, while the other two of its opposite edges have a linear profile. Multiple panels may be joined together by welding at the peripheral edges, to form a secure container. The composite material of the panel element in some forms, includes intrusion sensors, for example including optical fiber pathways at electrically conductive pathways, as well as processors for effecting data transfer and analyzes and secure communications. In some embodiments, the electrically conductive pathways include one or more bypass resistors to produce a different circuit resistance upon interruption of one or more of the pathways.

RELATED APPLICATION

This application claims priority to U.S. Provisional Patent ApplicationNo. 60/850,300, filed on Oct. 6, 2006, U.S. Provisional PatentApplication No. 60/872,956, filed on Dec. 4, 2006, and U.S. ProvisionalPatent Application No. 60/927,233, filed on May 2, 2007. Thisapplication is related to U.S. patent application Ser. No. 11/181,429,filed on Jul. 14, 2005 and U.S. Provisional Patent Application No.60/587,803, filed on Jul. 14, 2004. All above-referenced applicationsare incorporated herein by reference in their entireties.

This invention was made with Government support under Contract No.N66001-05-C-6014 awarded by the United States Navy. The Government hascertain rights in the invention.

FIELD OF THE INVENTION

The present invention relates to containers and more particularly tosecure containers that can withstand attempts at intrusion.

BACKGROUND

There has been a recognition that the United States is at risk of thedelivery of weapons of mass destruction to its ports by enemiesemploying a strategy of hiding such a weapon in a shipping container.Various schemes have been proposed for x-raying containers or otherwiseexamining containers as they are loaded on ships in foreign ports. Suchschemes, however, can be very limited in effectiveness since they can bedefeated with x-ray shielding, vulnerable to compromise by rogueemployees and the contents of the containers altered after they areloaded in a foreign port.

Approximately sixteen million twenty foot containers are in usethroughout the world. Additionally, approximately 40% of the personnelthat load and off-load these containers come from nations that are onthe terrorist list. Bribery and sabotage are common throughout theshipping industry, including government officials, shipping companiesand freight forwarders. Large quantities of contraband material now passthrough the maritime commerce into most ports in the U.S.

The current shipping containers are primarily made of steel withconsiderable drawbacks. The steel containers increase shipping weightsunnecessarily, wear out quickly and can be infiltrated by simple means.Other panels not made of steel have been considered, but they aretypically not made of weldable material. Without a strong weld, acontainer is susceptible to intrusion.

To a limited degree, the notion of enclosing detecting devices, such assensors or processors, in containers, which communicate with externalsystems, has been implemented in unsecure applications. For example,Sensitech, based in Beverly, Mass. (www.sensitech.com), providessolutions in the food and pharmaceuticals fields that are used formonitoring temperature and humidity for goods, in-transit, in-storage,and display. Such, temperature and humidity monitors are typicallyplaced in storage and transit containers to monitor if desiredconditions are maintained.

However, such data collection is not generally considered sensitive withrespect to security issues. Rather, it is used for ensuring thatproducts in a container do not spoil by being subjected to unfavorabletemperature and humidity conditions. Secure communications, tamperresistance, and detection are not particularly relevant issues in suchsettings. Additionally, such monitors do not monitor for the presence ofsuspicious content or materials, no matter where they may be introducedin the chain.

Even if detectors are introduced into a container and interfaced to anexternal system, an “enemy” may employ any of a variety of strategies todefeat such a detection system. For instance, an enemy may attempt toshield the suspicious materials or activities from the detectors; defeatthe communication interface between the detectors and the externalsystem, so that the interface does not report evidence of suspiciousmaterials or activities sensed by the detectors; disconnect thedetectors from the interface; surreptitiously load a container thatcontains an atomic weapon, but that does not contain detecting devices,onto a container ship; overcome external systems so that theyincorrectly report on the status of the detectors.

The present invention relates to a method of manufacturing,distributing, and utilizing shipping containers such that they may bemonitored for unauthorized access. The present invention also relates tomethods of making and utilizing inherently secure shipping containersthat improve shipping processes and provide a savings in the cost oftransportation, increased control, faster throughput, and reduction oflosses due to pilferage.

SUMMARY OF THE INVENTION

The present invention relates to a panel comprising multilayeredcomposite material that can be welded to other components, for exampleto a frame or to one or more panels to form a tamper-resistantcontainer, such as a shipping container. In addition, the panel maycontain embedded processors and sensors that can detect any intrusion ortampering with the container.

In one embodiment of the present invention, a panel includes a panelelement composed of a composite material formed from resin-infusedlayers of fiber material (such as glass fiber or polymer fiber). In thatembodiment, the panel element preferably has a four sided rectangularperipheral edge with two of the four side's edges being mutuallyopposite and extending along a first axis, and two of the four sidesedges being mutually opposite and extending along a second axis, whereinthe first axis is perpendicular to the second axis. The panel elementhas a substantially uniform thickness along a third axis, wherein thethird axis is perpendicular to the first and second axes. In a preferredform, the panel element has a corrugated profile along the first axis,and has a linear profile along the second axis.

The panel also has a first elongated edge element affixed to andextending from and along the first side edge of the panel element,wherein the first edge element has a corrugated profile along the firstaxis. A second elongated edge element, opposite the first side edgeelement, is affixed to and extends from and along the second side edgeof the panel element, wherein the second edge element has a corrugatedprofile along the first axis. A third elongated edge element affixed toand extends from and along the third side edge of the panel element, andwherein the third edge element has a linear profile along the secondaxis. A fourth elongated edge element, opposite the third side edgeelement, is affixed to and extends from and along the fourth side edgeof the panel element, and wherein fourth edge element has a linearprofile along the second axis. The panel element is composed of layeredcomposite material, and the first, second, third and fourth edgeelements and are composed of a weldable metal, for example, steel.

The edge elements may be coupled to in various manners to the panelelement. The edge element may extend from within the composite panelelement or may extend from the surface of an edge of a composite panelelement. The edge elements may also cover opposite surfaces of an edgeof the composite panel to provide a sandwich with the composite panelelement. To secure the edge element to the composite panel, an adhesiveor other material or a mechanical fastener is used to affix the edgeelement to the composite panel element.

A panel element may include a sensor system embedded therein. In apreferred form, the embedded sensor includes an array of one or moreoptical fibers. The array of optical fibers includes at least one fiberextending between two ends thereof, and arranged in a serpentineconfiguration. One of the ends of the fiber is adapted to receive anoptical signal so that the optical signal propagates along the opticalfiber toward to the other end. An optical signal generator is coupled toone end for generating the optical signal, and an optical signaldetector is coupled to other end for detecting optical signal. Theoptical signal generator may also be embedded in the panel element, andmay be adapted for remote activation. Alternately, the optical signalgenerator may be external to the composite panel element.

A panel element may include a sensor system formed by an array ofelectrical conductors. In a preferred form, the array of electricalconductors includes at least one electrical conductor extending betweentwo ends thereof, and arranged in a serpentine configuration. Theserpentine configuration includes at least one resistive bypass pathinterconnecting two points along said serpentine configuration. One ofthe ends is adapted to receive an electrical signal. An electricalsignal generator is coupled to the one end for generating an electricalsignal on the conductor and an electrical signal detector is coupled toother end for detecting the electrical signal. The electrical signalgenerator may be embedded in the panel element, and may be adapted forremote activation. Alternatively, the optical signed generator may beexternal to the composite material.

In another embodiment, a panel may include processors embedded in thecomposite material. In a preferred form, the processors are powered byan embedded battery connected to the processors. These processors aredistributed throughout the composite material in locations that arerelatively unlikely to be damaged during use. The processors can respondto sudden events and “wake up” in response to alarms to preserve thebattery. The wake up could result as result of an intrusion or as theresult of receipt of an externally generated RF trigger signal.

In another embodiment, the present invention may include a hybrid panelelement comprising a wood layer and a composite material layer formedfrom resin-infused layers of fiber material (such as glass fiber orpolymer fiber). The wood layer may be formed from plywood laminated witha thin reinforcing layer. The composite material layer includes a sensorsystem embedded therein.

In another embodiment, a number of panels of the invention may be joinedto form a container. The container may comprise a rectangularparallelepiped frame composed of a weldable metal, having four equallength parallel rails extending along each axis of an XYZ orthogonalcoordinate system. The sets of four equal parallel rails define invarious combinations, a first side panel locus, a second side panellocus, a first end panel locus, a second end panel locus, a top panellocus, and a bottom panel locus. Weldable panels, as defined above, aredisposed in each of the first side panel locus, second side panel locus,first end panel locus, second end panel locus, top panel locus, andbottom panel locus, and are welded at their respective peripheral edgeelements to the rails of the frame which define the respective panelloci. In one form of the invention, instead of a panel element asdefined above, forming the bottom panel, a hybrid panel element asdefined above forms the bottom panel. Further, one of the end panels mayinstead of being welded to rails, may be hingedly coupled to form a doorto the container. Alternative door and floor permutations may be used inother embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects, features and advantages of theinvention will be apparent from the following more particulardescription of preferred embodiments of the invention, as illustrated inthe accompanying drawings in which like reference characters refer tothe same parts throughout the different views. The drawings are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the invention.

FIG. 1 illustrates a front perspective view of a panel made ofmultilayered composite material into weldable edges, in accordance withthe invention;

FIGS. 1A and 1B illustrate exemplary corrugation profiles of the panelat FIG. 1;

FIGS. 2A-2G illustrate exemplary configurations for metal edges bondedto composite panel elements of the panel of FIG. 1;

FIG. 3 illustrates a cross-sectional view of a hybrid panel with a woodlayer with sensors;

FIG. 4 illustrates a front perspective view of a panel that includesembedded sensors and processors;

FIG. 5A-5E illustrate front perspective views of a variousconfigurations of a conductive grid within a composite panel;

FIG. 6 illustrates a front perspective view of a panel that includesembedded components and buses;

FIG. 7A illustrates a schematic diagram of a sensing circuit includingbypass resistors;

FIG. 7B illustrates a schematic diagram of one embodiment of a panelwith an embedded circuit including sensors and bypass resistors;

FIG. 7C illustrates a more detailed schematic diagram of one leg of theembedded circuit of FIG. 7B;

FIGS. 7D-7E illustrate schematic diagrams of various embodiments of apanel each having a different configuration of an embedded circuitincluding sensors and bypass resistors;

FIG. 8 illustrates a plan view of one embodiment of a circuit elementusing a wide conductor;

FIG. 9 illustrates a plan view of another embodiment of a panel with anembedded circuit including wide-conductor sensors and bypass resistors;

FIGS. 10A-10C illustrate the front panel embodiment of FIG. 9 with holesof various sizes and locations;

FIG. 11 illustrates a front right perspective view of a container;

FIG. 12 illustrates a front right perspective view of a containerincluding weldable composite sub-panels;

FIG. 12A illustrates a plan view of two adjacent composite subpanelsjoined together and including a jumper for electrically interconnectingembedded conductors of the adjacent subpanels.

FIG. 13 illustrates a detailed top view of two panels welded to theframe of a container;

FIG. 14A illustrates a detailed top, cross-sectional view of two panelsshown in FIG. 2B welded to the frame of a container,

FIG. 14B illustrates a detailed top, cross-sectional view of two panelsshown in FIG. 2C welded to the frame of a container; and

FIG. 14C illustrates a detailed top, cross-sectional view of two panelsshown in FIG. 2A welded to the frame of a container.

DETAILED DESCRIPTION OF THE EMBODIMENTS

A description of preferred embodiments of the invention follows.

The present invention relates to a panel comprising a panel elementformed by a multilayered composite material with edge elements extendingfrom its periphery, which are formed of a weldable material, such assteel to define a weldable panel. In the exemplary weldable panelsdescribed herein, the edge elements of the panels may be welded to edgeelements of a similar panel, as shown in FIGS. 12 and 12A (or to aframe, as shown in FIGS. 12, 13, and 14A-C) to form a tamper-resistantcontainer, such as a shipping container. The panels may be used forother purposes, such as a multipanel wall. The panel elements maycontain embedded processors or sensors that detect any intrusion ortampering with the panels.

In one embodiment of the present invention, a panel element is composedof a fiber-reinforced polymer composite material. The reinforced polymerstructure may comprise multiple layers of unidirectional fabric invarious orientations randomly oriented fabric or woven fabric encased ina resin matrix. In one embodiment, the reinforced polymer structure mayconsist of E-glass/vinylester composite (“Eglass Composite”), E-glassComposite has specific strength, impact, and durability properties thatexceed those of conventional steel.

Now referring to FIG. 1, an exemplary panel 10 is schematicallyillustrated with respect to an orthogonal coordinate system formed byaxes A1, A2, and A3. The panel 10 includes a central composite panelelement 11 having a four-sided rectangular peripheral edge PE. Two ofthe four sides edges S1, S2 are mutually opposite and extend along afirst axis A1, having lengths PE-L1. Two of the four sides S3, S4 aremutually opposite and extend along a second axis A2, having lengthsPE-L2. The panel 10 has a substantially uniform thickness PE-L3 along athird axis A3. The panel 10 has a corrugated profile along axis A1, anda linear profile along axis A2.

The corrugated profile of sides S1, S2 of the panel 10 is preferablysymmetrical about an axis A11 parallel to A1, as shown in FIG. 1A. Anasymmetrical corrugation profile may be employed in other embodiments.An exemplary sinusoidal corrugation profile is illustrated in FIG. 1A.An exemplary piecewise linear corrugation profile is illustrated in FIG.1B; while the junctions of the respective adjacent segments are shown as“sharp,” it will be understood that gradual curved junctions are withinthe scope of “piecewise linear” as used herein in FIG. 1B. Thecorrugated profile has a piecewise linear repeating patternX₁-X₂-X₃-X₄-X₅, wherein X₁ extends a distance D1 at a positive non-zeroangle P1 from A11. X₂ extends a distance D2 parallel to A11. X₃ extendsa distance D3 at a negative non-zero angle P2. X₄ extends a distance D4parallel to A11 and X₅ extends a distance D5 at a positive non-zeroangle P3 to A11. In one embodiment, it should be noted that D2=D4 andD1=D5=½ D3 and P1=P3=−P2.

Preferably, D1 sin P1 is in the range 0.25 in. to 4.0 in, D2 and D4 arein the range 1.5 in. to 8.5 in. and P1 is in the range 20° to 90°. Thereare three preferred forms of this geometry. The first preferred form,has dimensions D1 sin P1=1.42 in., D2=2.75 in and P1=27.9°. The secondpreferred form, has dimensions D1 sin P1=1.80 in., D2=4.33 in andP1=68.5°. The third preferred form, has dimensions D1 sin P1=0.79 in.,D2=6.00 in and P1=57°. In yet another form as may be used for a sidewall, the dimensions D1 sin P1=2.0 in., D2=2.75 in., and P1=47°.

The panel 10 includes a first elongated edge element ME-1 affixed to andextending from and along the first side edge S1, wherein the first edgeelement ME-1 has a corrugated profile along the first axis A1. A secondelongated edge element ME-2 is affixed to and extends from and along thesecond side edge S2, wherein the second side edge element ME-2 has acorrugated profile along first axis A1. The corrugation profiles of edgeelements ME-1 and ME-2 match the corrugation profile of panel element11.

A third elongated edge element ME-3 is affixed to and extends from andalong the third side edge S3, wherein third side edge element ME-3 haslinear profile along second axis A2. A fourth elongated edge elementME-4 is affixed to and extends from and along the fourth side edge S4,wherein fourth edge element ME-4 has a linear profile along second axisA2. The first edge element ME-1, second edge element ME-2, third edgeelement ME-3 and fourth edge element ME-4 are composed of weldablemetal, such as steel.

The edge elements (ME) may be joined to the edges of panel element 11 invarious manners. For example, the edge elements may be embedded in theedge of a panel as illustrated in FIG. 2C. The edge element (ME) mayalternatively be attached to a surface of an edge of the panel element,as shown in FIG. 2A. The edge elements (ME) may alternatively be bondedto the opposite surfaces of the edge of panel element 11 to provide a“sandwich” structure as shown in FIG. 2B. To secure the edge element tothe composite panel element, an adhesive, mechanical fastener, or bothmay be used to bond the edge element to the composite panel element.

In some embodiments, the edge elements (ME) follow the contour of thesurface respective surface. Referring to FIG. 2D, an edge view of aconnection between two adjacent corrugated composite panels is shown.The edge elements ME3 and ME4 are angled in a complementary manner, suchthat an edge element ME3 of a first panel overlaps a complementary edgeelement ME4 of a second adjacent panel. The overlapping joint can beformed using any of the options shown in FIGS. 2A through 2C. Thus, theresulting joint may reside along an equivalent D1 segment, such that acorrugation pattern of each individual subpanel is substantiallymaintained across the joined pair of subpanels.

An exemplary side or edge view of edge elements ME3 and ME4 at opposingends of a composite roof panel are shown in FIG. 2E and FIG. 2F. Anexemplary side edge element ME1 or ME2 of the composite roof panel isshown in FIG. 2G.

In a most preferred embodiment, the layered composite material formingpanel element 11 has a layer profile M₂/0₃/90/0/90/0₃/M₂ whereinsubscripts 2 and 3 denote two and three layers respectively, and whereinM denotes a mat fiber layer, 0 denotes a layer with longitudinal fiberorientation parallel to axis A2 and 90 denotes longitudinal fiberorientation perpendicular to the axis A2. In an alternative embodiment,a panel element 11 may have a layered composite material with a profile:M₂/90/0₃/0/0₃/90/M₂ wherein subscript 3 denotes three layers, andwherein M denotes a mat fiber layer, 0 denotes a layer with longitudinalfiber orientation parallel to axis A1 and 90 denotes longitudinal fiberorientation perpendicular to the axis A2. Also, a panel may have layeredcomposite material with a profile: M₃/0₃/0/0₃/M₃ wherein subscript 3denotes three layers, and wherein M denotes a mat fiber layer, 0 denotesa layer with longitudinal fiber orientation parallel to the axis A2 and90 denotes longitudinal fiber orientation perpendicular to the axis A2.The above three layer profiles provide robust panel elements and arepreferred in terms of strength and weight for conventional sizedcontainer applications, but other layer profiles may be used as well.Test results show better flexural and impact strength than conventionalsteel container walls.

As described above, the composite containers may include panels thathave the above-described configuration. However, in some configurationsof containers in keeping with the invention, an alternative panel may beused for the principal payload-bearing floor of a container. In suchcontainers, the floor panel may be a hybrid panel fastened to transversefloor joists, composed of an additional material along with afiber-reinforced polymer composite material, for example, a hybrid panelas described below.

Referring to FIG. 3, a hybrid panel is shown comprising a wood layer anda composite material layer bonded to the bottom side of the wood. Thewood layer is preferably ¾ inch laminated plywood including one or moreof hard and soft wood, solid-sawn tongue-and-groove hardwood planks, andpartially laminated solid-sawn hardwood. The composite material layer isa multilayer fiber/binder structure for example, E-glass/vinylester. Aswith the panels of FIG. 1, the hybrid panels can include a sensor systemembedded within the fiber-reinforced polymer composite layer. Thecomposite component of the hybrid panel provides a host environment forthe sensors, protects from the environment, and strengthens the wood inflexure, allowing percent weight reduction over conventional apitongplywood container floors.

In one embodiment, to meet the primary sensing objectives of breachdetection, the panels 40 may include a sensor system embedded thereinwhich can include a series of sensors, processors and data paths, seeFIG. 4. In one form, an advantage of embedding sensors, processors, andother devices in a hardened composite material is that the material actsas a protective coating, which protects the devices from the harshmaritime environment and from tampering. This approach is to becontrasted with placing intrusion sensing devices on existingcontainers, which do not present a protected environment to externallyapplied intrusion sensing devices. Another advantage of embeddingsensors in the container material is that the entire system can betested in the factory when the container is first constructed. In oneembodiment, the sensor system contains a grid of embedded array ofoptical fibers and optical sensors. The sensor system may be arranged ina number of different forms. In FIG. 5A, a panel 22 is shown having asingle fiber 24 in the form of a spiral, extending between opposite ends24A, 24B. An internal optical signal generator/detector 28 is coupled toends 24A, 24B. The generator/detector 28 is adapted to apply an opticalsignal to end 24A so that the signal propagates along fiber 24 to end24B where, provided the fiber 24 is intact, that signal is detected bygenerator/detector 28. In the event of a breach of the panel 22, theoptical fiber 24 would be interrupted so that an applied optical signalwould not reach to end 24B. The generator/detector 28 is adapted forremotely controlled operation (actuation and detection). While thegenerator/detector 28 in FIG. 5A is internal to (embedded in) panel 22,in other embodiments the generator detector is external to the panel 22.In such embodiments, the generator/detector 28 is adapted for remotelycontrolled operation. FIGS. 5B and 5C illustrate two otherconfigurations of fiber array. In FIG. 5B, a serpentine arrangement isshown where elements similar to elements in FIG. 5A are identified withthe same reference designation. Again, in FIG. 5B, thegenerator/detector 28 is embedded in panel 22. FIGS. 5C and 5Dillustrate embodiments similar to those in FIGS. 5A and 5B, but wherethe optical signal generator/detector 28 is external to panel 22.

In another arrangement, a panel may include a plurality of opticalfibers, each having a first end at an input port in the panel, andextending through panel to a second end at an output port in the panel.An optical driver having a light source is connected to the opticalfibers at the input port. Upon receiving a start or activating a signal(coded or uncoded), the driver causes radiation to propagate into theoptical fiber at its first end at the input port. An optical detector iscoupled to the output port to detect light propagating along the fiberfrom the input port. The two ends of optical fibers, in some forms, arecoupled to switches to permit selective input of light and detecting oflight. The switches pen-nit fibers to be pulsed under program controland allow a grid of fibers orthogonally extending (along “x” and “axe”)in the container walls. The x axis and y axis fibers are pulsed oractuated selectively under program control, so that the integrity of thevarious fibers is maintained in a manner permitting detecting of fiberbreaks or degradation and locating those breaks based on x and ycoordinating grid with this configuration. If an intrusion interrupts orstresses an optical fiber embedded in the composite material of thepanels, the use of x and y axes of fibers locates the intrusion. In somearrangements, processors are embedded in the composite material and areelectrically connected to the optical drivers. Many optical drivers maybe utilized in a container constructed of the composite material. FIG.5E illustrates a multi-fiber sensor array but without showing theoptical signal generators, detectors or switches.

In another form of the invention, the sensor system includes an array ofelectrical conductors. The array of electrical conductors includes atleast one electrical conductor extending between two ends thereof andarranged in multiple configurations. The electrical conductor array canhave the same configuration at the optical fiber arrays in FIGS. 5,5A-5E, and thus are illustrated in those figures. In one embodiment, theserpentine configuration includes at least one resistive bypass path(FIG. 7A) interconnecting between two points along said serpentineconfiguration. One of said points is adapted to receive an electricalsignal. The sensor system includes an electrical signal generatorcoupled to one end for generating an electrical signal and an electricalsignal detector coupled to said other end for detecting the electricalsignal. The electrical signal generator can be adapted for remoteactivation. Also, the detector can be adapted for remote activation.Both the electrical signal generator and the detector can be embedded inthe panel or external to the panel.

The processor and sensor type and the density of the processors andsensors in the container walls can be customized to meet a user's needs.Furthermore, in some designs, electrical paths and data paths andvarious data processing elements such as Complex Programmable LogicDevices (CPLDs) and/or Field Programmable Gate Arrays (FPGAs) or similarelements may be incorporated to provide control and communicationfunctionality. Additionally, to provide energy for these and similarsensors and elements, a power source such as a battery or rechargeablebattery may also be embedded in the composite materials. The batteriesfor powering the sensors and the processors and the light sources arepreferably rechargeable batteries, which can be periodically charged.The system is preferably provided with plenty of bandwidth and redundantprocessing power to fulfill the alerting, data acquisition, andcommunication requirements of a user.

Referring to FIG. 6, in another embodiment, a panel includes one or moreprocessors embedded into the composite material. The processors arepowered by a battery connected to the processors. These processors aredistributed throughout the composite material in locations that are lesslikely to be damaged during use. The processors can respond to suddenevents and “wake up” in response to alarms to preserve the battery. Thewake up may be the result of an intrusion or as the result of receipt ofan externally applied RF signal. In some embodiments, to reduce powerconsumption, the processors wake up on a regular basis. For example, theprocessor can periodically wake up and provide status, saying “here ismy ID, I'm okay.”

The processors have the ability to store data in flash memory and erasedata from flash memory. Consequently, they may be utilized to provide acoded unchanging ID, which is a number uniquely identifies a particularcomposite panel, and a certificate, which is a number given after apanel has been inspected, to a composite panel. In one embodiment, anetwork of processors are coupled together in a substrate grid. Thenetworked processors manage the detection grids and provide IDs andcertificates. Upon detection of an intrusion of the panel, the processormay completely destroy the value, IDs and certificates to preventspoofing of the panels.

Referring to FIG. 7A, in one form of the invention, the panel contains asensor system that includes a sensing circuit having an electricallyconductive path with multiple bypass resistors R₁, R₂, R₃, R₄ (generallyR). The electrically conductive path includes an array of electricallyconductive elements arranged in a circuit, such as a grid, spanning anarea of the panel. If the grid is intact, a substantial portion of theelectrical current flows through the electrically conductive elementsrather than through the bypass resistors R. Consequently, a resultingcircuit resistance measured at a pair of circuit terminals indicates ashort circuit with a measurable resistance being that of theelectrically conductive paths themselves. When the conductive path isbroken, at least a portion of the current is then diverted through oneor more of the bypass resistors R. The resultant change in resistance isthen detectable by a resistance-monitoring circuit.

In some embodiments, the circuit is planar, spanning a substantial areaof the panel. In the exemplary embodiment of FIG. 7A, the array ofelectrical conductive elements are arranged in a series configurationextending between a pair of sensing terminals. The array of electricallyconductive elements can be arranged, as shown, to include a serpentinepattern. A first bypass resistor R₁ is coupled between two points alongthe conductive path, such that a portion of the conductive path betweenthe two coupled points covers a first area of the panel. Similarly, theremaining bypass resistors R₂, R₃, R₄ are each respectively coupledbetween two different points along the same conductive path.

In the exemplary embodiment, a break in the panel interrupts theconductive path and results in current being diverted through therespective bypass resistor R. Thus, a break in the first area of thegrid will result in current flowing through the first bypass resistorR₁. A resulting resistance measured at the circuit terminals will changefrom a short circuit to approximate the value of R₁. As multiple areasof the same grid are broken, the current will be diverted through one ormore additional bypass resistors R. The resulting circuit produces avoltage drop that depends upon the combination of bypass resistorsthrough which the current is flowing. Should one or more breaksinterrupt conductive paths in other areas of the exemplaryseries-configured sensing circuit, voltage drop at the terminals will bethe sum of the voltage drops across all of the bypass resistors throughwhich current is flowing. In some embodiments, one or more of the bypassresistors provide different resistive values that can be used toidentify locations of one or more areas of the panel that are breached.

An exemplary embodiment of a panel sensing circuit including bypassresistors is shown in FIG. 7B. The sensing circuit includes a serpentineconductive path spanning a substantial region of a composite panel. Theserpentine path includes multiple U-shaped circuit legs L₁, L₂, L₃, . .. (generally L) coupled together in a series configuration. Each of thecircuit legs L is connected in a parallel or shunt configuration to arespective bypass resistor R₁, R₂, R₃, . . . (generally R). The seriescircuit formed by the serpentine conductive path and bypass resistors Ralso includes a pair of terminals. A break in any one of the circuitlegs L will result in a diversion of electrical current from the leg andthrough the bypass resistor R.

A schematic diagram of one of the legs L and its interconnected shuntresistor R is shown in more detail in FIG. 7C. An input current inenters a first node. According to well-established circuit principles,the input current is equivalent to the sum of the currents exiting thenode including a bypass current I_(B) flowing through the bypassresistor and the leg current I_(L) flowing through the circuit leg L. Ina non-breached configuration, the majority of current flows through thecircuit leg, such that I_(L)=I_(in), producing a negligible voltage dropV_(L) due to resistance of the electrical conductor. However, if thecircuit is breached, the current flows through the bypass resistor, suchthat I_(R)=I_(in). Consequently, the voltage drop increases according tothe value of the bypass resistor (V=I_(in)/R). If more than one circuitlegs are breached, the measured circuit resistance will vary in relationto the resulting circuit configuration.

In some embodiments, the sensing circuit is embedded within aninsulating material forming the panel. Alternatively or in addition, atleast a portion of the sensing circuit can be attached to a surface ofthe insulating material of the panel. Such insulating material caninclude resin-infused layers of fiber material, such as any of thecomposite materials described herein. In some embodiments, the panelincludes a second insulating material, such as wood.

In some embodiments, the circuit terminals are connected to externalelectronics for determining the resistance of the circuit. In otherembodiments, the circuit includes electronics coupled to the pair ofterminals for determining the resistance of the circuit. The electronicscan include a signal generator providing an electrical current to thesensing circuit. Alternatively or in addition, the electronics caninclude a detector for measuring a voltage across the pair of terminals.In some embodiments, the electronics includes a controller fordetermining a resistance based on the generated current and detectedvoltage.

One such controller is the 16F684 microcontroller, commerciallyavailable from Microchip Technology, Inc. of Chandler, Ariz. Thecontroller promotes low power consumption, requiring approximately 100microamperes during a reading. The readings can be accomplished in muchless than 1 millisecond. In some embodiments, readings are performed ata rate of one per second. The average current is virtually zero.

Alternatively or in addition, the electronics includes a radiotransmitter configured to temporarily operate in a low-power “sleep”mode to conserve power. The transmitter can be used to forward readingresults from the microcontroller to an external receiver. Theelectronics optionally include a radio transmitter also configured totemporarily operate in a low-power “sleep” mode. The entire electronicspackage can be powered using two D-cell batteries, with an expectedbattery lifetime of about five years or more.

In some embodiments, one or more of the panels are connected to at leastone other panel of the same container using jumper leads. For example,one panel including an embedded sensor system and controllingelectronics can be electrically connected to another panel through oneor more jumper leads. Thus, in some embodiments, electronics in onepanel can be used to perform measurements on more than one panels.

FIG. 7D illustrates another embodiment of a composite panel providing asensing circuit having a different configuration including multipleinterconnected loops L1, L2, L3, . . . (generally L). More specifically,the loops are arranged in a spiral configuration terminating at a pairof circuit terminals. Each loop L extends around the spiral and isinterconnected to an adjacent loop by a respective bypass resistor R1,R2, R3, . . . (generally R). Without interruption to the conducting pathof the circuit, the majority of current flows through the spiralelement, such that a resistance detected at the terminals approximates ashort circuit. Interruption of one or more of the loops L; however,results in the loop current flowing through one or more bypass resistorsR associated with the interrupted loop(s). Consequently, a circuitresistance measured at the terminals increases from the short-circuitvalue, depending upon the values of the one or more bypass resistors nowcarrying current.

The delectability of various sized and shaped panel breaches, or holes,can be controlled to some extent according to a selected configuration,orientation, and spacing of electrically conductive path of the sensingcircuit. Referring again to FIG. 7B, a panel breach having a diameterless than the spacing ‘d’ between adjacent circuit legs may be detectedif a portion of the hole coincides with the electrical conductor.However, it would not be possible for such a hole to remain undetectedas long as it did not interrupt the electrically conductive path. Apanel breach in the form of an elongated hole or slit having a lengthgreater than ‘d’ may remain undetected if properly aligned betweenconductive paths.

FIG. 7E illustrates an embodiment of a composite panel with yet anotherdifferent sensing circuit configuration including a horizontallydirected serpentine pattern overlaying a vertically directed serpentinepattern. Such a configuration forms a rectangular grid capable ofsensing a breach of the panel in more than one direction. Thus, althoughan elongated breach having a length greater than ‘d’ may be undetectedby one of the two different patterns, it will be detected by the other.In some embodiments, the two patterns are provided between differentlayers of the resin-infused layers of fiber material providingelectrical insulation between the two different patterns.

It would also be possible for a breach or hole having a diametersubstantially less than the spacing ‘d’ to be detected if it happened tocoincide with the conductive path, thereby interrupting the flow ofcurrent. Consequently, there is no assurance of a minimum-sized detectedhole.

Referring to FIG. 8, an alternative embodiment of a sensing circuitincludes an electrically conductive path in which the electricalconductors are formed to have a wide, ribbon-like configuration. Asshown, the electrically conductive path is formed using a conductorhaving a width ‘w’. It would be impossible for any panel breach, orhole, having a maximum dimension less than the conductor width ‘w’ tocompletely interrupt current flow along any one of the conductive paths.Thus, selection of a conductor width ‘w’ can be used to eliminatedetection of individual holes of sizes less than the conductor widthsize. In the illustrative example, a conductor having a width of 1.25inches prevents detection of any holes less than 1.25 inches indiameter.

The distance between adjacent legs of the sensing circuit can also beused in combination with the conductor diameter to set a limit for whicha minimum detectable hole size will always be detected. Namely, a holesized greater than twice the width plus the separation distance “d”between adjacent conductors (i.e., 2w+d) will always interrupt at leastone of the conductors. In the exemplary embodiment, a 3 inch hole willalways interrupt at least one of the two 1.25 inch wide conductorsseparated from each other by 0.5 inches.

The wide conductors can be porous, including openings distributed acrossthe width of the conductor. In some embodiments, the wide conductors areformed from a wire mesh or screen. When used in combination withcomposite panels, the wide conductors can reside substantially withinthe composite panel (e.g., between resin-infused layers of fibermaterial). That configuration is particularly amenable to use in acomposite material, as the resin binder can readily permeate theconductive element minimizing any tendency for delamination of acomposite panel.

Sensing circuits including wide electrical conductors can also be routedin a variety of configurations and optionally combined with bypassresistors. In some embodiments, the bypass resistors are themselvesprovided to have a substantial width. Wide bypass resistors reduce thepossibility that a panel breach having a hole below the minimumdetectable hole size will cause an interruption because it happened tocoincide with a narrow bypass resistor. As shown, a bypass resistorhaving a width of 4 inches can be combined with the exemplary circuitadapted to consistently detect holes equal to or greater than 3 inches,without detecting holes less than 1.25 inches in diameter. Wide bypassresistors can also be provided with an open structure including pores orapertures.

FIG. 9 illustrates an unbroken electrical path having a serpentineconfiguration and using an electrically conductive screen providing awide conductor. Two resistive elements are included towards either edgeof the serpentine configuration and selectively coupled to one or moreof the multiple serpentine circuit legs. In FIG. 10A, a panel breachinterrupts two legs of the serpentine circuit. A resulting interruptionto current flowing in the effected legs, now open circuited, causescurrent to flow through the identified bypass resistors. The resultingcircuit configuration can be schematically represented as a firstresistor shunting a series combination of two other resistors. If all ofthe resistors are provided with the same resistance R, the effectiveresistance of the resulting circuit would be ⅔ R. The same circuit isagain shown in FIG. 10B with a second smaller hole. The resultingcircuit configuration can be schematically represented as the equivalentcircuit of FIG. 10A combined in series with a parallel combination oftwo additional bypass resistors that are associated with the secondhole. The effective resistance is 1.17R.

FIG. 10C illustrates the same circuit as in the above examples having alarge hole coincident with one of the resistive elements. Current flowsin the resulting circuit through three of the bypass resistors on theopposite side of the panel from the hole, resulting in an effectiveresistance of 3R. As demonstrated, holes of various size, combination,and location will generally produce different circuit resistance values.This allows for an association of a measured resistance to a hole of aparticular size and/or location.

Each conductive element in any of the above embodiments has a respectiveimpedance that is substantially less than a bypass resistor R. Forexample, the conductive elements are formed from a material generallyknown as a good electrical conductor. Examples of good electricalconductors include metals, such as copper, aluminum, gold, silver, andnickel; metal alloys, such as bronze; and combinations thereof.

Bypass resistors can include standard carbon-based resistorconfigurations, such as carbon composition, film, and wire woundresistors, and combinations thereof. In some embodiments, the bypassresistors can include a carbon-based material having a flat, orribbon-like geometry.

The panel of FIG. 1 may be used to form a container 60. In one form, sixpanels are affixed to a frame 62 such as that shown in FIG. 11. Theframe 62 is a rectangular parallelepiped frame composed of a weldablemetal, and having four equal length parallel rails RX1, RX2, RX3, andRX4 extending along an X axis. Another set of four equal length parallelrails RY1, RY2, RY3 and RY4 extends along a Y axis. Also, four equallength parallel rails RZ1, RZ2, RZ3 and RZ4 extend along a Z axis,wherein said X, Y, and Z axis are mutually orthogonal. The rails RX1,RX2, RY1, and RY2 define a first side panel locus. The rails whereinRX3, RX4, RY3 and RY4 define a second side panel locus. The rails RY1,RY3, RZ1, and RZ2 define a first end panel locus. The rails RY2, RY4,RZ3, and RZ4 define a second end panel locus. The rails RX2, RX4, RZ2,and RZ4 define a top panel locus. The rails RX1, RX3, RZ1 and RZ3 definea bottom panel locus.

To construct a container 60 on frame 62, panels of the type shown inFIG. 1 are sized to fit the corresponding loci defined by the framerails, and welded to those rails of frame 62. For example, a first panel80 is disposed in the first side panel locus, and welded at itsperipheral edge elements ME to said rails RX1, RX2, RY1, and RY2. FIG.13 illustrates an exemplary welding joint formed between edge element MEand frame 62. That weld extends between the weldable metal that extendsfrom the panels element of the panel. Similarly, a weldable panel isdisposed in the second side panel locus and welded at its peripheraledge elements ME to rails RX3, RX4, RY3, and RY4. Another weldable panelis disposed in said first end panel locus and welded at its peripheraledge elements ME to rails RY1, RY3, RZ1, and RZ2. Another weldable panelis disposed in the top panel locus and welded at its peripheral edgeelements ME to rails RX1, RX4, RZ2, and RZ4. The container may furtherinclude another weldable panel disposed in the bottom panel locus andwelded at its peripheral edge elements ME to rails RX1, RX3, RZ1, andRZ3. Alternatively, hybrid reinforced wood panels may be fastened to thefloor joists using conventional mechanical fasteners used in existingconstruction of floors. A container further includes a weldable paneldisposed in second end panel locus and welded at its peripheral edgeelements ME to rails RY2, RY4, RZ3, and RZ4. Any one or more, of thepanels can alternatively be hingedly coupled to the frame to form a doorfor the container. Exemplary welding joints between the panels of FIG.2B and a steel frame are shown in FIG. 14A; between the panels of FIG.2C and the steel frame are shown in FIG. 14B; and between the panels ofFIG. 2A and the steel frame are shown in FIG. 14C.

In one arrangement, a composite container is constructed to have a shapeand size similar to a standard steel shipping container so that thecomposite container can be used interchangeably with conventional steelshipping containers. In this case, the perimeter frame is made oftypical steel members used on conventional ISO steel shippingcontainers. Composite containers of the invention may be stacked andloaded similar to conventional steel containers, using conventionalloading equipment.

In some embodiments, two or more weldable sub-panels can be combined,such that the combination is sized to fit the corresponding loci definedby the frame rails. As shown in FIG. 12, multiple weldable sub panelsare combined along a common side panel of a standard shipping container.The use of sub panels can simplify sparing, as spared components can besmaller in size. Alternatively or in addition, the use of sub panels canreduce maintenance costs as damage can be corrected using smaller panelsegments.

A groove and flange design may be incorporated in the container panelsto provide electrical power and data paths which will interconnect stackcontainers, allowing communications amongst and between the containers,and in some cases, establishing a network. Alternatively or in addition,a jumper can be used to interconnect embedded conductors of differentcomposite panels. An exemplary embodiment is shown in FIG. 12A includinga jumper provided between adjacent subpanels. The two subpanels arejoined with a fillet weld along adjoining metal flanges providing apanel-to-panel connection. A jumper is used to span the joint. Thejumper is connected at either end to a respective embedded conductorwithin each of the adjoining subpanels. In some embodiments, screwterminals are provided on the subpanel providing access to the embeddedconductors. Thus, a conductive jumper interconnects the embeddedconductors by simply connecting to the exposed screw terminals of a pairof adjacent subpanels.

In some embodiments, a composite joint is formed along respective edgesof two adjoining subpanels. The composite joint includes embedded wiresthat can be used to provide connectivity between the adjacent panels. Aconductive element, such as the jumper can span the composite joint, andcan be screwed into each of the adjacent subpanels, thereby providing aconnection from the panel to the joint.

A single assembled container may be positioned and connected to acontainer rack. In some arrangements the rack may be connected to a PCor other similar digital device that is capable of accessing theInternet. Along with supplying Internet access, rack may also supplypower to the container (along with other containers). By connecting thecontainer (or containers) to rack, signals and/or messages thatrepresent a container condition (e.g., the status of the container) maybe sent to a remote computer system or server.

Along with sending information to remote locations, components may beembedded in the panels of a container for storing the information forlater retrieval. Furthermore, information may be uploaded to theassembled container under control of a remote server. As mentionedabove, individual CPLDs may be embedded in panels, and these CPLDs maybe used to inexpensively implement relatively high data rates withinterfaces implementing one or multiple protocols.

The sensor arrays in the panels of the invention are configured so thata hole on any of the six faces of the container larger than apredetermined detectable size, for example, 9 square inches, can bedetected immediately when the hole is cut under circumstances of lightor darkness and under any loading condition. Also, conductive serpentinegrid bonds with widths of at least about 18 inches prevent falsepositives so that holes of sizes less than 9 inches do not alarm thesystem.

In an alternative form, the container wall contains plugs through whichprocessors and other sensors can be coupled, thereby providing acompletely modular approach that can be upgraded as new technologybecomes available. The processor or processors, using modular standardinterfaces manage the sensors, alerting, external communications, andsecurity functions.

In one arrangement, the container system is provided with a securitysystem designed on the assumption that the container may be in thephysical possession of criminals or terrorists or other persons withhostile intent. This level of security substantially exceeds securitybased on the assumption that outsiders are attacking a safe interiorcore. In one example) the security system includes software,cryptographic tokens, and other types of data that may be securelyprovided from a remote monitoring station.

Composite container may include other sensors for detecting the openingof one or more doors, movement, extreme environmental conditions, sealstatus, and other conditions that may be of interest to a customer. Inone arrangement, the sensors are embedded in the panels. Alternatively,the sensors may be attached to or plugged into the panels and may beremoved from the walls. The composite containers also can be providedwith RFID tags and/or RFID monitoring devices or other similar systems.

The sensors and processors in composite container may be further capableof detecting a breach of any of the six walls of the container under anyload conditions. The anti-breach system can be tuned to a point wherethe rate of false positives is acceptably low by using wide bypassresistors and wide conductive grid bands. Embedding the sensors andprocessors in the container walls also protects the sensors andprocessors both from sabotage and from the harsh maritime environmentwhen the containers are in use. In one arrangement, the compositecontainer walls are provided with a modular design with attaching means,for example, holes, so that additional equipment (e.g., sensors and orprocessors) can be rapidly and easily attached to or plugged into thewalls, to account for the development of new technologies and/or toconfigure the container for a specific type of cargo or a specificsituation. For example, an empty container might need simpler, lessexpensive instrumentation than a container full of cargo.

The embedded power and data paths inside the containers preferably areaccessible from external sources via inductive couplings, allowing for(a) recharging the power (batteries), (b) forming hard wired data andelectrical paths, and (c) building a communication network within astack composed entirely of composite containers, which can be used tocount the number of the containers and detect the interposition of roguecontainers in the stack. The security system may enable the automaticinstallation of different software modules immediately before acontainer is loaded and the use of several processors inside thecontainer, which continuously check on one another and provide statusand feedback information.

The container, in some examples, is an integral unit that includes fourwalls (a front wall, two end or side walls, and back wall), a roof (ortop), a floor (or bottom). In one embodiment, the container has at leastone door. According to another embodiment, the container preferably hasat least two doors and one end. Again, in one arrangement, the doorsinclude a coupling that permits the flow of optical and electrical dataand electrical power to and from the doors. Additionally, oralternatively, a similar coupling may be used on the bottom of thecontainer to permit the flow of optical and electrical data andelectrical power to or from a similar (or complementary) coupling on thetop of an adjacently positioned container, for example, or from a rackon which containers are stacked, or from a truck chassis on which acontainer is placed. Again, additionally, or alternatively, the adjacentcomplementary couples permit optical and/or electrical signal flowbetween and through various containers in a stack.

The data coupling incorporates a coupling mechanism that, if needed,withstands the harsh rigors of the maritime environment, where heavycontainers may be stacked on top of one another and on truck chassis bycrane. In an alternative embodiment, electrical couplings transferringpower to a container by inductance is used with the container. Data ismodulated over such a coupling to provide a data transfer method. Forthe door, optical signals/data can be coupled through butt joints offiber optical paths, for example, or by effervescent light coupling.

In some arrangements, detectors for sensing special nuclear materialsmay be embedded into the composite panel walls. For example, relativelyinexpensive domestic sensors may be embedded. In some conventionalsystems, special nuclear materials may be shielded. However, forsufficiently small container sizes, shielding may be impractical. Incontrast, an appropriate number of small individual containers withembedded domestic sensors may provide a useful strategy for reducing therisk of nuclear weapons being imported through a maritime transport.Under this strategy, shipments that contain cargo in volumes that mightbe feasible for adequate shielding or special nuclear materials may needspecial handling.

In another application, after contents have been placed in a container,the container may be locked and sealed under control of a remote server.During this procedure, cryptographic material, randomly produced by theremote server may be uploaded into the container and stored in anappropriate FPGA or CPDL device embedded in one or more of the containerwalls.

When an unauthorized condition occurs, such as a breach of the containerwall or an unscheduled opening of the container, the intrusion may besensed by the embedded sensors internal of the container and embeddedcryptographic material is partially or completely destroyed. Due to thisprocedure, an adversary may be unable to restore cryptographic materialor determine the state of the container prior to the intrusion.Additionally, a signal or message may be sent to a remote server toindicate that an alarming condition has been detected. In somescenarios, the remote control server may ask for a hash of thepreviously supplied cryptographic values, to which, if an alarm hasoccurred, the container may be unable to supply that information.

Referring back, each individual container may include slots that arecapable of receiving fork lift tongs to that the containers may be movedindividually or as a stack. Since, as mentioned above, the contents andcondition of a container or a stack of containers may be queried by aremote computer system via an embedded or attached data interface,containers and stacks of containers may be moved and inventoried whilebeing monitored.

Other types of sensors and detectors may be incorporated into acontainer or a stack of containers. For example, a sensor may beincluded that determines the weight of the container and store data thatrepresents this weight. Alternatively, a previously sealed container maybe weighed by a separate device, and this information may then be storedin the container. Additionally, information such as data from domesticsensors, weight information, the supposed contents of the container,etc. may be fused together and processed to develop a metric to identifythe likelihood that the container contains a nuclear device or otherharmful contraband.

In general, commerce flows in world commerce are typically uneven, withmore goods flowing in one direction than another. Consequently, thecapability to ship disassembled containers is vital. Thereby, in somearrangements individual panels with embedded sensors may be shipped toparticular locations (e.g., shipping ports, airports, etc.) forassembling at a later time. Since individual panels may be shippedseparately, prior to assembling containers, the individual panels may beinserted into a rack for testing (e.g., pass a check-out procedure) by aremote server to determine if the panel is functioning correctly.Furthermore, composite containers may be partially or completelyassembled in a rack for testing by a remote computer system to determineif the container is functioning properly.

A container rack may be implemented for various platforms andfacilities. For example, a container rack may be designed and producedfor positioning on truck chassis, a ship cargo compartment, a factoryfloor, etc. so that monitoring may continue during loading andoff-loading periods and during transit. To provide power during theseperiods, the container rack may be designed to supply power (along withdata connectivity) to a stack of containers (e.g. a stack of eightcontainers) that is held by the rack.

In some arrangements, a container that is produced from compositematerial may be produced in which the sides, the roof, the floor, thefront and back, and doors may be disassembled into panels andreconstructed as needed. By manufacturing and distributing panelsproduced from composite material, the panels may be easily assembled ata shipping site into an appropriate container size. This container, onceassembled, may be lighter than a similar container made of steel and mayhave more strength. Additionally, the container may be able to withstandthe elements of a marine environment, and may be cost competitive.

In some arrangements, multiple composite containers may be verticallystacked so that an upper-positioned container securely mates with thecontainer located directly below. By mating containers, a portion of astack or a complete stack of containers may be lifted and moved as asingle unit. This design has the advantage of reducing the cost ofshipping empty containers back to the point of origin, because thedisassembled parts are more compact for shipping purposes than the emptycontainers. This also reduces the risk of terrorists and otheradversaries hiding people or contraband in empty containers. Anotheradvantage is that refurbishment and maintenance is possible at the panellevel rather than the container level. Discrete panels can be employedor not, depending on a user's desire to trade off advantages anddisadvantages (such as a container made this way might not be as strongas a container manufactured as a unit, and the additional complexity ofinterfacing the electrical, optical, and power paths through wallscomposed of separate panels, and that such a device might be more easilyreverse engineered by an adversary.

In some arrangements, the composite container may include an embeddedwireless fidelity (WIFI) device that is capable of communicatingexternally without needing to rely on optical and electrical coupling.Furthermore, in some arrangements, the composite container includes anembedded telecommunication device (e.g., a radio frequency transceiver)for communicating with a loading crane and/or other ground- (orterminal-) based equipment.

According to another preferred embodiment, the sensors and processors ofa stack of composite containers are interconnected and a data path andoptionally an electrical path is formed by the interconnectedcontainers, so that a system that includes the stacked compositecontainers is able to count the number of containers and detect theinterposition of a rogue container that lacks conforming communicationinformation and status information from that container, aid distributeelectrical power to other containers as well.

According to another arrangement, the sensors and processors of multiplecomposite containers, which are stored in a stack, are interconnectedand a data path is formed by the interconnected containers, so that asystem that is formed by the sensors and processors of the stackedcomposite containers. This system of sensors and processors is able tocount the number of containers and detect interposition of a roguecontainer that lacks conforming communication information and statusinformation of the processors and sensors from that container. Inanother embodiment, the interchangeably conventional steel containersare provided with communication links and/or sensors and or processors,so that in a stack of containers, which includes both the compositecontainers and the steel containers, the steel containers canintercommunicate with the composite containers, and the compositecontainers and the steel containers form a communication network.

In some arrangements, two or more of the containers in a container stackare interconnected and thus form a communication network, which may becapable of counting the number of the containers and detecting theunauthorized inserting of a rogue container into a stack of containerson a platform such as a ship.

Composite containers (assembled above) may be vertically stacked uponone another. In some arrangements, an assembled container may mate witha container positioned below by using the flange and groove designdescribed above. By mating the stacked containers, power and/or dataconnections may be made between the containers so that power and/orinformation may be passed among hardwire or wireless paths thatinterconnect the stacked containers.

A rack of stacked containers may be provided, as previously mentioned,in which each container is connected (directly or indirectly) to one ormore remote servers (via the Internet) for sending and/or receivinginformation. In one scenario, this exemplary arrangement may be used tomonitor the interposition of rogue containers in a stack of containers.Rogue containers are containers that are not remotely controlled, and,for example, may contain contraband such as nuclear weapon or toxicmaterial. In some arrangements, a stack of containers and a rack may bedesigned to fit into a twenty-foot or forty-foot ISO shipping container.In this illustrative example, the containers are approximately four feethigh so that a stack of two containers plus rack may be inserted into aten-foot high ISO container. If a rogue container, which is notconnected to a remote server, is inserted into or positioned on top ofthe stack, the entire stack may not fit in the ISO container and therebybe detected. If a rogue container is interchanged with a container inthe stack, due to absence of a connection with the remote server, theserver may determine the present of the non-conforming container.

For a stack of ISO containers, the interposition of a non-conformingcontainer into the middle of the stack may be relatively quicklydetected by a remote controller that is connected to the stack throughthe Internet. Detection of a rogue container placed on top of the stackmay be detected by incorporating a device (e.g., pressure sensor) thatis connected to the stack and detects any non-conforming device placedon top of the stack. In other arrangements, this capability may beincorporated into the top side of composite containers used to in placeof the conventional ISO shipping containers.

While this invention has been particularly shown and described withreferences to preferred embodiments thereof, it will be understood bythose skilled in the art that various changes in form and details may bemade therein without departing from the scope of the inventionencompassed by the appended claims.

What is claimed is:
 1. A weldable hybrid composite panel suitable forforming a container, the panel comprising: a four sided composite panelelement, each side defining a side edge, the composite panel elementbeing made of fibrous reinforcement layers encased in a resin matrix;and weldable metallic elongated edge elements extending along and one offixed to the side edges of an outside surface of the panel element andextending from a periphery of the panel element, each of the weldableelongated edge elements having a profile that is the same as a profileof its respective side edge; wherein the weldable elongated edgeelements are structured to enable the composite panel to be welded atits peripheral edges.
 2. The weldable hybrid composite panel of claim 1in which two of the four side edges have a corrugated profile; and theweldable elongated edge elements extending along and fixed to the sideedges having the corrugated profile and having the same corrugatedprofile as the corrugated profile of the two corrugated side edges,thereby presenting a corrugated weldable edge.
 3. The weldable hybridcomposite panel of claim 2 in which the two side edges having thecorrugated profile are opposite each other with respect to the compositepanel.
 4. The weldable hybrid composite panel of claim 1 in which theedge elements extend from within the composite panel element.
 5. Theweldable hybrid composite panel of claim 1 in which the edge elementscover opposite surfaces of a side edge of the composite panel to providea sandwich attachment with the composite panel element edge.
 6. Theweldable hybrid composite panel of claim 1 in which an adhesive or amechanical fastener is used to attach the edge element to the compositepanel element.
 7. The weldable hybrid panel of claim 2, wherein thecorrugated profile of the peripheral edge is symmetrical about an axisparallel to one of the side edges of the panel having the corrugatedprofile.
 8. The weldable hybrid panel of claim 2, wherein the corrugatedprofile of the peripheral edge is sinusoidal.
 9. A weldable hybridcomposite panel comprising: a composite panel element having a four sideedges defining a peripheral edge, two of the four side edges having acorrugated profile and two of the four side edges having a linearprofile, the composite panel element being made of fibrous reinforcementlayers encased in a resin matrix; first weldable metallic elongated edgeelements extending along and fixed to the side edges having thecorrugated profile, the first weldable metallic elongated edge elementshaving the same corrugated profile as the corrugated profile of the twocorrugated side edges; and, second weldable metallic elongated edgeelements extending along and fixed to the side edges having the linearprofile, the second weldable elongated edge elements having the samelinear profile as the linear profile of two linear side edges; whereinthe first and second weldable metallic elongated edge elements arepositioned such that they are one of fixed to the side edges of anoutside surface of the panel element and extend from a periphery of thepanel element; and wherein the first and second weldable metallicelongated edge elements enable the composite panel to be welded at itsperipheral edges to other panels to form a container, wherein the twoside edges having the corrugated profile are opposite each other withrespect to the composite panel.
 10. The weldable hybrid composite panelof claim 9 in which an adhesive or a mechanical fastener is used toattach the first and second weldable metallic elongated edge element tothe composite panel element.
 11. A weldable hybrid composite panelcomprising: a composite panel element having a four sided peripheraledge, two of the four side edges having a corrugated profile and two ofthe four side edges having, a linear profile, the composite panelelement being made of fibrous reinforcement layers encased in a resinmatrix; first weldable elongated edge elements extending along and fixedto the side edges having the corrugated profile, the first weldableelongated edge elements having the same corrugated profile as thecorrugated profile of the two corrugated side edges; and, secondweldable elongated edge elements extending along and fixed to the sideedges having the linear profile, the second linear weldable elongatededge elements having the same linear profile as the linear profile oftwo side edges; wherein the first and second weldable elongated edgeelements are positioned such that they are one of fixed to the sideedges of an outside surface of the panel element and extend from aperiphery of the panel element; and wherein the first and secondweldable elongated edge elements enable the composite panel to be weldedat its peripheral edges to other panels to form a container, and whereinthe corrugated profile of the peripheral edge has a piecewise linearrepeating pattern.
 12. The weldable hybrid panel of claim 11, whereinthe panel has an axis parallel to one of the side edges of the panelhaving the corrugated profile, and wherein the corrugated profile has apiecewise linear repeating pattern consisting of 5 legs, X1, X2, X3, X4,and X5, wherein: X1 is not parallel to the axis, and extends a distanceD1 at a positive non-zero angle P1 from the axis; X2 is parallel to theaxis, having a length D2, and is spaced apart from the axis; X3 is notparallel to the axis, and extends a length D3 at a negative non-zeroangle P2 from the axis; X4 extends parallel to the axis, having a lengthD4, and is spaced apart from the axis; and X5 is not parallel to theaxis, and extends a length D5 at a positive non-zero angle P3 from theaxis.
 13. The weldable hybrid panel of claim 12, wherein D2=D4;D1=D5=½D3; and P1=P3=−P2.
 14. The weldable hybrid panel of claim 12,wherein D1 sin P1 is within the range of from about 0.25 in to about 4in; D2 and D4 are within the range of from about 1.5 in to about 8.5 in;and P1 is in the range 20° to 90°.
 15. The weldable hybrid panel ofclaim 12, wherein D1 sin P1=1.42 in; D2=2.75 in; and P1=27.9°.
 16. Theweldable hybrid panel of claim 12, wherein D1 sin P1=1.80 in; D2=4.33in; and P1=68.5°.
 17. The weldable hybrid panel of claim 12, wherein D1sin P1=0.79 in; D2=6.00 in; and P1=57°.